JPH05138034A - Modified zeolite alkylation catalyst and method for its use - Google Patents

Abstract

PURPOSE: To provide a molecular sieve catalyst comprising a lanthanum/beta zeolite, particularly useful for the alkylation of an aromatic substrate in the liquid phase by a low molecular weight alkylating agent. CONSTITUTION: The catalyst is characterized by containing a metal-modified beta zeolite composed of lanthanum/beta-zeolite having a content of lanthanum preferably about 0.05 to 0.5 weight %. This lanthanum/beta catalyst is provided firstly by treating original zeolite beta through ammonium exchange, calcining dry powder obtained thereby to burn out organic mold, and treating the calcined powder through ammonium exchange again. Then, the lanthanum/beta catalyst is manufactured by adding lanthanum to the above zeolite system by ion- exchange method. Then, a binder is added next. The obtained mixture is pelletized by a proper measure. The pellet obtained is formed into an active LaH-beta form by calcining.

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION This invention relates to improved metal-modified alkylation catalysts and methods of using the same. The catalysts are lanthanum / particularly useful in the liquid phase alkylation of aromatic substrates with low molecular weight alkylating agents.
Contains beta zeolite.

[0002]

Background of the Invention The process of alkylating aromatic feedstocks and the use of molecular sieves as catalysts in the alkylation process are known in the art. Such alkylation processes can be used to produce mono- and / or poly-alkylated products in the low to high molecular weight range, and can be used in gas phase, liquid phase, or both liquid and gas phase. It can be carried out under the existing intermediate conditions.

US Patent No. 4, to Young,
301,316 discloses the use of crystalline zeolite alkylation catalysts in the alkylation of benzene with relatively long chain alkylating agents having one or more reactive alkyl groups having at least 5 carbon atoms. .. The reactants may be either in the gas phase or the liquid phase, and the zeolite catalyst may be modified or unmodified. Suitable zeolite catalysts include zeolite beta, Z
Included are SM-4, ZSM-20, ZSM-38, and their synthetic and naturally occurring isotopes, such as zeolite Omega. Zeolites can be subjected to various chemical treatments and can be subjected to steam or heat treatments such as calcination in air, hydrogen or an inert gas. What is specifically disclosed in the Young patent is:
Reaction of benzene and 1-dodecene at 250 ° C. and 600 psig in a flow reactor.

US Pat. No. 4,185,040 to Ward et al. Has a low sodium content which is said to be particularly useful in the production of ethylbenzene from benzene and ethylene and the production of cumene from benzene and propylene. Discloses an alkylation process using the molecular sieve catalyst of US Pat. The Na ₂ O content of the zeolite should be less than 0.7% by weight, and preferably less than 0.5% by weight. Examples of suitable zeolites include
Hydrogen Y zeolites which include X, Y, L, B, ZSM-5, and omega crystalline type molecular sieves and are steam stabilized are preferred. The alkylation process is preferably carried out under conditions such that at least a portion of the liquid phase is present until at least substantially all of the olefin alkylating agent has been consumed.

Another alkylation step is described in US Pat. No. 4,798,81 to Ratcliffe et al.
6 and 4,876,408. Ratcliffe et al. Have used molecular sieve alkylation catalysts treated in such a way as to improve their selectivity towards monoalkylation, especially benzene propylation to produce cumene. Selectivity is said to be increased by a value of at least 1% by first depositing a carbonaceous material on the catalyst and then subjecting the resulting carbon-containing catalyst particles to combustion. Particularly disclosed zeolite crystalline molecular sieves include those selected from the group of Y zeolites, fluorinated Y zeolites, X zeolites, zeolite beta, zeolite L and zeolite omega. Zeolites can also be modified to produce products with reduced alumina content and reduced sodium content.

Aromatic alkylation reactions, such as the alkylation of benzene with ethylene, are highly exothermic reactions. Thus, the alkylation reaction can be carried out in several stages with an intermediate cooling stage. For example, U.S. Pat. No. 4,107,224 to Dwyer
Disclosed is the gas phase ethylation of benzene over a zeolite catalyst in a downflow reactor with intermediate injection of cold reactants into a diluent. Disclosed specifically is an intermediate stage injection of ethylene and benzene. Deuyer has identified catalysts suitable for use in his invention as having a constraint index in the range of approximately 1-12. Suitable zeolites having a constraint index in parentheses are ZSM-5 (8.3), ZSM-11 (8.
7), ZSM-12 (2), ZSM-35 (4.5),
ZSM-38 (2) and similar materials. In particular, various molecular sieves such as Zeolite Beta (constraint index 0.6) are disclosed as having constraint indices outside the range suitable for the Duyer ethylbenzene manufacturing process.

US Pat. No. 4,891,458 to Innes discloses an aromatic hydrocarbon with a C ₂ -C ₄ olefin alkylating agent under at least partial liquid phase conditions using zeolite beta as a catalyst. The present invention relates to a method for alkylation or transalkylation of

[0008]

SUMMARY OF THE INVENTION In accordance with the present invention, there are provided metal-modified alkylation catalysts and methods of using the catalysts in the alkylation of aromatic substrates with relatively low molecular weight alkylating agents. The catalyst is preferably used under mild temperature conditions, including liquid phase conditions, but the catalyst can also be used in gas phase operation. The catalyst is characterized by having a lanthanum content of metal-modified zeolite beta, preferably between about 0.05 and 0.5% by weight and preferably about 0.1% by weight. Contains lanthanum / beta zeolite. It is preferred to modify the beta zeolite with lanthanum, but other metals such as calcium and barium can also be used.

The lanthanum / beta catalyst of the present invention first undergoes ammonium exchange of the original zeolite beta, calcining the resulting dry powder to burn the organic template, further calcining the powder to ammonium exchange, and It can then be produced by adding lanthanum to the zeolite system by the ion-exchange method. Then add the binder,
The mixture is then pelletized by any suitable means. Subsequent calcination brings the catalyst to its active LaH-beta form.

In practicing the process of this invention, a feed containing an aromatic substrate is fed to the reaction zone and contacted with a molecular sieve alkylation catalyst containing a lanthanum / beta zeolite. The lanthanum / beta zeolite preferably has a lanthanum content of about 0.1% by weight and is further based on crystalline zeolite beta of at least 500 m ² / gram, more preferably at least 650 m ² / gram. It is also characterized by its surface area. Also C ₂ -C ₄ alkylating agent, preferably fed into the reaction zone which is operated at temperature and pressure cause alkylation of the aromatic substrate in the presence of an alkylation catalyst while maintaining the aromatic substrate in the liquid phase To be done. The resulting alkylated aromatic substrate is then recovered from the reaction zone.

A preferred application of the present invention is in the alkylation of benzene with ethylene to produce ethylbenzene. The process is carried out in the liquid phase as described above and under alkylation conditions such that the xylene produced is 0.03 wt% or less based on the amount of ethylbenzene produced. In another aspect of the invention, the liquid phase alkylation is a C ₂ -C ₄ alkylation in such a way that at an average temperature of 300 ° C. or less, at least 1 mol% of the alkylating agent is dissolved in the aromatic substrate. It is carried out using a series of linked reaction steps operating with intermediate step injections of agent. A flow chart showing a preferred embodiment for carrying out this alkylation process by using a plurality of series of linked reaction steps is currently in pending application no.
1,500, the entire disclosure of which is hereby incorporated by reference.

[0012]

DETAILED DESCRIPTION The present invention relates to improved alkylation catalysts and methods of using the catalysts. Suitable catalysts include lanthanum / beta zeolites which are particularly useful in the alkylation of aromatic substrates with low molecular weight alkylating agents. The present invention is particularly applicable to the ethylation of benzene under mild liquid phase conditions with low or no xylene production, and the invention is particularly described with respect to the production of ethylbenzene. However, other alkylation reactions can also be used in the practice of this invention. For example, the invention can be applied to the reaction of propylene with benzene to produce cumene. Also, olefinic alkylating agents are commonly used, including alkynes, alkyl halides, alcohols, ethers and alkynes such as those disclosed in US Pat. No. 3,551,510 to Pollitzer et al. Other alkylating agents such as esters can also be used. Other aromatic substrates such as toluene and xylene can be subjected to alkylation according to the present invention. Furthermore, although the invention is particularly useful for liquid phase operation, it is also possible to use the gas phase or mixed liquid / gas phases.

It has previously been shown that the H-form of zeolite beta is a very good catalyst for liquid phase alkylation. However, the preferred lanthanum / beta catalysts of the present invention show better selectivity for xylene formation than their hydrogen counterparts.

The lanthanum / beta zeolite of the present invention is
It can be produced by modifying crystalline zeolite beta. The basic process for producing crystalline zeolite beta identified by x-ray diffraction pattern is Wadlinger (Wadlinge).
r) disclosed in US Pat. No. 3,308,069 to others. In addition, European patent application 159,846 to Reuben discloses the synthesis of zeolite beta with a silica / alumina molar ratio of up to 300 by using a templating agent prepared by the combination of dimethylbenzylamine and benzyl halide. ing. Another method of making zeolite beta is described in European patent application 165,20 to Bruce et al.
8, European Patent Application 186,447 to Kennedy et al., And US Pat. No. 4,642,226 to Calvert et al. Each of these steps is known in the art and suitable for making crystalline zeolite beta useful in the present invention, and the entire disclosure of the above patents is hereby incorporated by reference.

The original zeolite beta catalyst used in the present invention is most preferably of very low sodium content. Low sodium content zeolite betas per se are known in the art (US Pat. No. 3,308,069 to Waddlinger et al. And 4, to Calvert et al.
642,226), the preferred original zeolite beta used in the present invention is characterized by a substantially lower sodium content than that disclosed in Waddlinger et al. And Calvert et al. Preferably, the original zeolite beta used in the present invention has a sodium content, expressed as Na ₂ O, of 0.04% by weight or less and most preferably 0.02% by weight or less. There is. Such suitable original zeolite betas are also characterized by a very high surface area, in particular of at least 600 m ² / g based on crystalline zeolite beta.

The preferred original zeolite beta is prepared by a series of ion-exchange and calcination steps carried out using synthetic zeolite as the starting material. Synthetic zeolite beta is a reaction mixture consisting of silica, alumina, sodium or other alkyl metal oxide, and an organic templating agent according to any suitable process, such as those disclosed in the U.S. patents to Waddinger et al. And Calvert et al., Supra. It can be produced by hydrothermal digestion.

Typical digestion conditions include temperatures ranging from just below the boiling point of water at atmospheric pressure to about 170 ° C. above the vapor pressure of water at the temperature of inclusion. The reaction mixture is subjected to mild agitation for a period ranging from about 1 day to several months to obtain the desired crystallinity for producing zeolite beta. Relatively low temperatures generally require relatively long periods to reach the desired crystal formation. For example, about 100
At a temperature of ° C, crystal growth occurs for a period in the range of about January to April, but near the upper limit of the above range, for example 160 ° C, the digestion period is 1 or 2 days to about 1 week. At intermediate temperatures of about 120 ° -140 ° C, the digestion period extends for about 2-4 weeks.

Suitable templating agents can be used in the preparation of the zeolite beta molecular sieve crystalline structure, and tetraethylammonium hydroxides and halides are suitable templating agents as demonstrated by the above references. Classes such as tetraethylammonium chloride, dibenzyldimethylammonium hydroxide, or dibenzyldimethylammonium chloride are included. The reaction components can be varied according to techniques known in the art to provide zeolite beta products of various silica / alumina ratios. Typically, the reaction products used to synthesize zeolite beta molecular sieves will contain formulations within the following molar ratio ranges:

[0019]

[Table 1] Table _{I SiO 2 / Al 2 O 3} : 20-1000 H 2 O / SiO 2: 5-200 OH - / SiO 2: 0.1-0.2 M / SiO 2: 0.01-1 .0 R / SiO _2: in 0.1-2.0 table I, R is nitro organic templating agent, for example a tetraethylammonium group, and M is an alkali metal ion, typically as sodium It does not have to be so. For further description of zeolite beta and methods of its synthesis, use may be made of the above-mentioned patents and patent applications, including in particular US Pat. Yes, and their full disclosure is provided here for reference.

The first beta zeolite preferably has a silica to alumina ratio of about 20:50. The freshly synthesized zeolite beta is first subjected to an ion exchange step using an ion exchange medium such as an aqueous solution of an inorganic ammonium salt such as common ammonium nitrate. After the ion exchange treatment, the zeolite beta is calcined at a maximum temperature of about 570 ° C. for a period of 2 hours or more. After calcination, the zeolite beta is cooled and subjected to another ion exchange treatment, which can be carried out with the same inorganic ammonium salts as above. At the end of the second ion exchange treatment, the zeolite beta will generally have a surface area at least twice that of the original starting material and a very low sodium content. The sodium content, calculated as Na ₂ O, will be below 0.04% by weight, and generally below 0.02% by weight. Additional similar ion exchange treatments can be used after the second ion exchange treatment. After drying, lanthanum is then added into the zeolitic system by the ion exchange method using a lanthanum salt solution.

The lanthanum / beta zeolite is mixed with a binder such as alumina sol, gamma-alumina or other refractory oxides to produce a kneaded lanthanum / beta zeolite-binder mixture. The mixture is then pelletized by a suitable technique such as extrusion and the pellets formed are then dried. At this point, the pelletized binder-lanthanum / beta zeolite product is calcined under conditions sufficient to decompose ammonium ions on the active sites, leaving the lanthanum / beta zeolite in the active LaH-beta form. ..

In the experimental work carried out with respect to the invention,
A lanthanum / beta zeolite catalyst was used in the reaction of ethylene and benzene to produce ethylbenzene. The original zeolite beta catalyst was prepared by using multiple ion exchange and calcination steps as described above.
produced. The original beta zeolite is about 25 silica /
It has an alumina ratio, contains tetraethylammonium hydroxide as the retained templating agent, and has an initial surface area of 210 m ² / g and an N of about 0.5-1%.
It had a sodium content of a ₂ O. The first ammonium ion exchange treatment was carried out by immersing the zeolite catalyst in an aqueous solution of ammonium nitrate having a normality of 2 at a ratio of zeolite to ammonium nitrate of about 2: 3. Zeolite beta was immersed in the ion exchange medium under gentle stirring at 85 ° C. for a period of 2 hours. Zeolite beta was then filtered and dried at 110 ° C for at least 2 hours. The dried powder was calcined to a programmable temperature to a maximum temperature of 570 ° C to burn the organic mold. This calcined powder is then 2
Ion exchange was performed with ammonium ions in the same manner as above for one continuous ion exchange. The surface area at the end of the second ammonium exchange step was 750 m ² / g. The sodium content was 0.01% by weight or less of Na ₂ .

Lanthanum was added into the zeolite system by the ion exchange method. The 80 g of anhydrous NH ₄ / Beta zeolite was suspended in deionized water. 1.247 g of La a (NO _{3) 3} by dissolving in deionized water were prepared salt solution of lanthanum nitrate. This salt solution was added slowly to the zeolite suspension at a temperature of about 90 ° C. The exchange continued for about 3 hours. The La-exchanged zeolite is filtered, washed, and 110 ° C.
Dried at. This powder form (La / NH ₄ beta-
Chemical analysis of (Zeolite) is given below and it shows a La content of about 0.1% by weight.

Chemical analysis of La / Beta zeolite (anhydrous basis): Sample _{weight% SiO 2 / Al 2 O 3} Si Al La Na * K * La / NH 4 beta 43.2 2.7 0.12 0 0 30.9 * <0.01% powdered lanthanum / beta zeolite (66.7 g, anhydrous basis) was the nitric acid treatment It was kneaded with alumina (21.9 g, anhydrous basis) and extruded into 1/16 inch pellets. The resulting extruded zeolite pellets were then calcined in a furnace in air at a programmed temperature up to 530 ° C. During the calcination of the extrudate at 530 ° C., the La / NH ₄ beta catalyst thus
a ³⁺ / H- beta is converted into ^{_{(La 3+ = La 2 O 3}} ) catalyst, NH ₃ occurs ^{_{[NH 4 + → NH 3 +}} H +]. Finally the catalyst had the physical properties of the following: surface area = 609.1m ² / g, fine pore area = 325.0m ² / g, pore volume = 0.13 ml / g, average pore diameter = 33. 1A.

The experimental work with lanthanum / beta zeolites was carried out in an upflow reactor heated by a sand bath set at a nominal temperature of 200 ° C.
The reactor contained 9.06 grams of catalyst. Benzene at the bottom of the reactor 12.2 hours space velocity (LHSV)
At a rate such as to provide benzene / ethylene molar ratio of 9.5 with supplementation of -1, the actual molar ratio varied from about 9.4 to 9.6 during the experimental run.
For comparison purposes, lanthanum-free H-beta zeolite was used under the same alkylation conditions as the lanthanum / beta catalyst. The results of the above experimental work are set forth in Table II below and graphically shown in FIG. Effluent analysis is given in wt% for benzene and ethylbenzene and various other components. The total xylene yield for the entire experiment is also shown in Table II and Figure 1.

[0026]

[Table 2] Table II Time, Time PPM xylene Time, time PPM Xylene H-beta Ethylbenzene LA- beta Ethylbenzene 1.00 192.74 0.5 85.21 1.90 221.09 1.0 62.90 2.90 103.43 1.5 55.18 20.40 67.23 2.0 56.20 14.15 74.75 2.5 55.78 26.15 72.45 3.0 54.50 42.45 57.63 21.5 62.49 47.15 72.54 24.5 54.39 50.00 73.67 45.0 46.94 67.50 58.97 49.5 47.91 71.25 57.63 68.3 46.28 90.50 50.73 75.0 40.07 97.25 59.20 94.0 0.00 99.0 0.00 Examine the experimental data shown in Table II and the ethylene loadings for the reactor. 12 of benzene in stoichiometric equivalent
Given that it is slightly less than%, it can be seen that the lanthanum beta zeolite catalyst is highly active and exhibits good selectivity for ethylbenzene production. The activity of the catalyst remained substantially unchanged after the experimental work period.

In the practice of the present invention, the alkylation reaction is carried out at a reaction temperature which ensures that the liquid phase remains in the reactor at a pressure well above the vapor pressure of the aromatic substrate. To provide a complete liquid phase reaction, an overflow bed system is used in which the catalyst bed is completely submerged in liquid. This can easily be done using upflow techniques such as are used in laboratory work, and this would generally be preferred in the practice of the invention. However, a downflow overflow bed operation can also be performed by adjusting the exit flow rate to ensure that the catalyst bed is covered by liquid benzene or other aromatic substrate.

Preferably, stepwise reactions are performed to ensure good dissolution of ethylene (or other alkylating agent) in benzene (or other aromatic substrate) to carry out the entire reaction in the liquid phase. The method used. Moreover, the use of multiple stages provides an in-stage cooling opportunity where the adiabatic reactor is used, or even allows the use of several isothermal reaction stages. As mentioned above
Such a stepwise reaction scheme is disclosed in co-pending application no. 371,500. It is also preferred to dehydrate the raw materials before use in the present invention. The process for performing such dehydration to reduce the water content is described in co-pending application no. 371,581, the entire disclosure of which is hereby incorporated by reference.

While particular embodiments of the present invention have been described, it will be appreciated by those skilled in the art that such modifications are suggested, and all such modifications are within the scope of the claims. It is something that enters.

The main features and aspects of the present invention are as follows.

1. A molecular sieve catalyst containing lanthanum / beta zeolite.

2. The molecular sieve catalyst of claim 1 having a lanthanum content of between about 0.05-0.5% by weight.

3. A molecular sieve catalyst as described in 1 above, having a lanthanum content of about 0.1% by weight.

4. The surface area of the molecular sieve is the lanthanum /
At least 6 based on the crystalline structure of beta zeolite
The catalyst of 1 above, which is 50 m ² / g.

5. The molecular sieve contains lanthanum / beta zeolite in combination with a binder, and the surface area of the lanthanum / beta zeolite is based on the composite of the molecular sieve containing the binder. At least 45
The catalyst of 1 above, which is 0 m ² / g.

6. The lanthanum / beta zeolite is 0.0
Having a sodium content of Na ₂ O of 4% by weight or less,
The molecular sieve catalyst of the above item 1.

7. The molecular sieve catalyst as described in 6 above, wherein the sodium content is 0.02% by weight or less of Na ₂ O.

8. In a process for producing a lanthanum / beta zeolite derived by modifying an alkali metal-containing zeolite beta synthesized by hydrothermal digestion of a reaction mixture consisting of silica, alumina, an alkali metal oxide, and an organic templating agent. And (a) treating the synthesized zeolite beta with an ion-exchange medium to protonate a portion of the active sites in the zeolite by exchanging the alkali metal, and (b) the ion-exchange under anhydrous conditions. The treated zeolite at 400 ° -70
Calcining at a temperature in the range of 0 ° C. for a period in the range of 2-10 hours, and (c) treating the calcined zeolite with an ion-exchange medium to separate another part of the active sites in the zeolite. Is protonated by exchanging the alkali metal,
(D) calcining the ion-exchanged zeolite from step (c) under anhydrous conditions at a temperature in the range 400 ° -700 ° C. for a period in the range 2-10 hours,
(E) Adding lanthanum into the zeolite system by treating the ion-exchanged zeolite from step (d) with an ion-exchange medium containing a lanthanum salt solution to obtain a lanthanum / beta zeolite, (f ) Mixing the lanthanum / beta zeolite with a binder to produce a shaped lanthanum / beta zeolite binder mixture, and (g) pelletizing the lanthanum / beta zeolite binder mixture and drying the resulting pellets. Such as including.

9. Further, the pellets were 520 ° -580.
The method of claim 8 including the step of calcining to a temperature in the range of ° C for a period of 2-4 hours.

10. The method of 8 above, wherein the ion-exchange medium used in step (a) is an aqueous solution of an ammonium salt.

11. The method according to 8 above, wherein the ion-exchange medium used in step (c) is an aqueous solution of an ammonium salt.

12. The method of 8 above, wherein the lanthanum salt solution used in step (e) is an aqueous solution of lanthanum nitrate.

13. In a liquid phase alkylation process for aromatics, step (a) feeding a feed containing an aromatic substrate to a reaction zone and contacting with a lanthanum / beta alkylation catalyst,
(B) a C ₂ -C ₄ alkylating agent is supplied to the reaction zone,
(C) operating the reaction zone at a temperature and pressure which keeps the aromatic substrate in the liquid phase and causes alkylation of the aromatic substrate with the alkylating agent in the presence of the catalyst; and (d) Recovering an alkylated aromatic substrate from the reaction zone.

14. The surface area of the catalyst is at least 650.
The method according to 13 above, which is m ² / g.

15. The molecular sieve composite wherein the alkylation catalyst comprises the lanthanum / beta zeolite in combination with a binder, and the surface area of the lanthanum / beta zeolite comprises the binder. The method of 13 above, which is at least 450 m ² / g, based on

16. The lanthanum / beta zeolite is 0.
The method of 13 above, having a sodium content of Na ₂ O of 04 wt% or less.

17. The lanthanum / beta zeolite is 0.
The method of 13 above, having a sodium content of Na ₂ O of 02 wt% or less.

18. The method according to 13 above, wherein the lanthanum / beta zeolite catalyst has a lanthanum content of 0.05 to 0.5% by weight.

19. The lanthanum / beta-zeolite catalyst according to claim 13, wherein the lanthanum content is about 0.01% by weight.
the method of.

20. The method of 13 above, wherein the aromatic substrate comprises benzene and the alkylating agent is an ethylating or propylating agent.

21. The method according to 20 above, wherein the alkylating agent is an olefin.

22. The alkylating agent is ethylene,
21. The method according to 21 above.

[Brief description of drawings]

FIG. 1 is a graph showing the results of a benzene alkylation experimental run with ethylene over the catalyst of the present invention compared to unmodified zeolite beta.

 ─────────────────────────────────────────────────── ───Continued from the front page (72) Inventor Thomas Ross Schieler, Texas, USA 77547 Galena Park Northmain 400 (72) Inventor Asim Kumar Gosseille, Texas, USA 77062 Hiuseton Mabley Mill Road 1627

Claims (2)

[Claims] 1. A molecular sieve catalyst comprising lanthanum / beta zeolite. 2. A method for producing a lanthanum / beta zeolite derived by reforming an alkali metal-containing zeolite beta synthesized by hydrothermal digestion of a reaction mixture consisting of silica, alumina, an alkali metal oxide, and an organic templating agent. And (b) treating the synthesized zeolite beta with an ion-exchange medium to protonate a portion of the active sites in the zeolite by the exchange of the alkali metal, and (b) the ion-exchange under anhydrous conditions. The calcined zeolite in the zeolite by calcination at a temperature in the range of 400 ° -700 ° C. for a period in the range of 2-10 hours, and (c) treating the calcined zeolite with an ion-exchange medium. Another portion of the active site of ## STR1 ## is protonated by the exchange of the alkali metal, and (d) the ion-exchange from step (c) under anhydrous conditions. The calcined zeolite at a temperature in the range of 400 ° -700 ° C. for a period in the range of 2-10 hours, and (e) the ion-exchanged zeolite from step (d) comprising a lanthanum salt solution. Lanthanum is added to the zeolite system by treatment with an ion-exchange medium to obtain a lanthanum / beta zeolite, and (f) the lanthanum / beta zeolite is mixed with a binder to form a shaped lanthanum / beta zeolite binder. Producing a mixture, and (g) pelletizing the lanthanum / beta zeolite binder mixture and drying the resulting pellets.